Process for the manufacture of electrophoretic displays

ABSTRACT

This invention relates to processes for the manufacture of electrophoretic displays.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 10/845,295,filed on May 12, 2004, now U.S. Pat. No. 7,052,571. This applicationalso claims the priority under 35 USC 119(e) of U.S. ProvisionalApplication No. 60/570,845, filed May 12, 2004. The contents of bothapplications are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

a) Field of the Invention

This invention relates to processes for the manufacture ofelectrophoretic displays, in particular, multi-color and sectionalelectrophoretic displays.

b) Description of Related Art

The electrophoretic display (EPD) is a non-emissive device based on theelectrophoresis phenomenon of charged pigment particles suspended in asolvent. It was first proposed in 1969. The display usually comprisestwo plates with electrodes placed opposing each other, separated byspacers. One of the electrodes is usually transparent. Anelectrophoretic fluid composed of a dielectric solvent with chargedpigment particles dispersed therein is enclosed between the twoelectrode plates. When a voltage difference is imposed between the twoelectrode plates, the pigment particles migrate to one side or the othercausing either the color of the pigment particles or the color of thesolvent being seen from the viewing side.

There are several different types of EPDs. In the partition type EPD(see M. A. Hopper and V. Novotny, IEEE Trans. Electr. Dev.,26(8):1148-1152 (1979)), there are partitions between the two electrodeplates for dividing the space into smaller cells, in order to preventundesired movement of particles, such as sedimentation. The microcapsuletype EPD (as described in U.S. Pat. Nos. 5,961,804 and 5,930,026) has asubstantially two dimensional arrangement of microcapsules each havingtherein an electrophoretic composition of a dielectric solvent and asuspension of charged pigment particles that visually contrast with thedielectric solvent. Another type of EPD (see U.S. Pat. No. 3,612,758)has electrophoretic cells that are formed from parallel line reservoirs.The channel-like electrophoretic cells are covered, and in electricalcontact, with transparent conductors. A layer of transparent glass fromwhich side the panel is viewed overlies the transparent conductors.

An improved EPD technology was disclosed in a co-pending application,U.S. Ser. No. 09/518,488 filed on Mar. 3, 2000 (corresponding to WO01/67170), the content of which is incorporated herein by reference inits entirety. The improved EPD cells are prepared by, for example,microembossing a layer of a thermoplastic or thermoset precursorcomposition coated on a first substrate to form microcups ofwell-defined shape, size and aspect ratio. The microcups are then filledwith an electrophoretic fluid and top-sealed with a polymeric sealinglayer. A second substrate is laminated over the filled and sealedmicrocups, preferably with an adhesive layer.

The microcup-based multi-color electrophoretic display has manyadvantages. For example, when the microcup dimensions are formed tomatch the size of the sub-pixels intended for the red, green and bluecolor on a thin film transistor backplane, they can be filledindividually with the red, green and blue colored electrophoretic fluidsto correspond to the geometric arrangements of the sub-pixels on the TFTbackplane. This feature allows the possibility of true multi-colordisplays with active matrix driving. Examples of the driving schemes forthe multi-color microcup-based electrophoretic displays are described indetail in co-pending applications, U.S. Ser. No. 10/198,729 filed onJul. 16, 2002 (corresponding to WO03/009059) and U.S. Ser. No.10/222,036 filed on Aug. 16, 2002 (corresponding to WO03/016993), thecontents of both of which are incorporated herein by reference in theirentirety.

From the manufacture point of view, accurate placement of a minuteamount of electrophoretic fluids into the designated microcups istheoretically achievable with current technologies. Inkjet printing hasbeen considered as a possible candidate for this task because of itsability to precisely deliver a predetermined volume of a fluid in theform of tiny droplets of a well-control size. The tall partition wallsof the microcup-based electrophoretic displays appear to also provide agood mechanism to prevent splash and mixing of inkjet-printedelectrophoretic fluids. However, there are several very challengingprocessing issues to be solved before the roll-to-roll manufacturing ofmulti-color electrophoretic displays can be implemented.

First, the diameter of the charged pigment particles in theelectrophoretic fluids is typically in the range of tenths of a micronto several microns. Plugging of the inkjet head nozzles could be a majorreliability problem, particularly if the pigment particles have atendency to flocculate or aggregate during use or storage.

In addition, when a dielectric solvent of low surface tension, such as aperfluorinated or hydrocarbon solvent, is used in the electrophoreticfluids, there are additional difficulties because of the low surfacetension of the solvent. The preferred surface tension of conventionalinkjet inks or fluids is typically in the range of 30˜45 dyne/cm. Theextremely low surface tension (in the range of 14˜30 dyne/cm) ofdielectric solvents, particularly the perfluorinated solvents, doespresent a major problem in the control of the droplet breakdown process.For example, when a perfluorinated solvent is used in an electrophoreticfluid, it is difficult to maintain a negative surface pressure to keepthe electrophoretic fluid inside the nozzle. Furthermore, undesirabledrying and particle deposition on the nozzle head would occur because ofthe capillary effect that encourages an outward material flow to thenozzle surface. Therefore, it has been very difficult to manufactureelectrophoretic displays with high efficiency and reliability wheninkjet printing is involved in the filling of the electrophoreticfluids, particularly when a dielectric solvent of low surface tension isused.

Also, in the roll-to-roll manufacturing process for microcup-basedelectrophoretic displays, the electrophoretic fluid filling process isimmediately followed by a sealing process. When the microcups in oneparticular area on the web are filled with slightly more fluids thannecessary, there is the possibility of “overflow” of the fluids in thisarea to the adjacent microcups before or during the subsequent sealingstep. The “overflow” of an electrophoretic fluid of one color toadjacent microcups containing electrophoretic fluids of other colorsmeans intermixing of different colors, which inevitably would result inreduction of the color purity of the display manufactured therefrom.Therefore, there has been a strong need for a roll-to-roll manufacturingprocess for multi-color electrophoretic displays with a wider processwindow to ensure product quality.

SUMMARY OF THE INVENTION

The first aspect of the present invention relates to a process for themanufacture of a multi-color electrophoretic display involving addingcolorant solutions or dispersions of different colors and chargedpigment particles in separate steps. More specifically, the processcomprises a first step of pattern-wise filling colorant solutions ordispersions into microcups in predetermined areas, for example, byinkjet printing. The second step is the pattern-wise or non-pattern-wiseadding an electrophoretic fluid comprising charged pigment (e.g., TiO₂or other white or colored pigments) particles dispersed in a dielectricsolvent or solvent mixture into the microcups which are pre-filled withthe colorants.

The carrier solvent used in the colorant solutions or dispersions may bethe same or different from the dielectric solvent or solvent mixture inthe electrophoretic fluid. If the carrier solvent in the colorantsolutions or dispersions is different from the dielectric solvent orsolvent mixture, it would act only as a carrier for the colorants and isevaporated after having delivered the colorants to their designatedlocations.

The colorants in the microcups are re-dissolved or re-dispersed backinto the electrophoretic fluid after the electrophoretic fluid is addedin. The thus filled microcups are then top-sealed by one of the sealingprocesses as described in this and related applications.

The second aspect of the present invention relates to a process for themanufacture of an electrophoretic display comprising microcups filledwith electrophoretic fluids of different electrophoreticcharacteristics, such as switching rate, threshold voltage, gamma and/orclearing voltage. The process comprises the steps of pattern-wisefilling microcups by, for example, inkjet printing, with additivesolutions or dispersions providing the various characteristics, followedby pattern-wise or non-pattern-wise adding an electrophoretic fluidcomprising charged pigment (e.g., TiO₂ or other white or coloredpigments) particles dispersed in a dielectric solvent or solvent mixtureinto the microcups which have been pre-filled with the additivesolutions or dispersions. The thus filled microcups are then top-sealedby one of the sealing processes as described in this and relatedapplications.

Useful additives for the present invention may include, but are notlimited to, surfactants, protective colloids, polymers, viscositymodifiers, charge controlling agents, stabilizers, antioxidants,fluorescent materials, fillers and filler particles. Specific examplesof useful additives may include, but are not limited to, those disclosedin co-pending patent applications, Ser. No. 10/335,210 filed on Dec. 31,2002, Ser. No. 10/335,051 filed on Dec. 31, 2002, Ser. No. 10/632,171filed on Jul. 30, 2003, Ser. No. 10/683,869 filed on Oct. 9, 2003, Ser.No. 10/686,501 filed on Oct. 14, 2003, Ser. No. 10/976,152 filed on Oct.27, 2004 and Ser. No. 10/976,244 filed on Oct. 27, 2004, the contents ofall of which are incorporated herein by reference in their entirety.

The processes of the first and second aspects of the invention asdescribed above may also be suitable for the manufacture of sectionalelectrophoretic displays.

The processes of the present invention have many advantages. Forexample, the surface tension and rheology of the colorant or additivesolutions or dispersions to be filled may be optimized independentlyfrom the electrophoretic fluid. This provides a much wider processwindow to find a suitable precision placement method. Secondly, ifinkjet printing is used, the risk of plugging the inkjet nozzles by thepigment particles is significantly reduced. Thirdly, the processes arecompatible with the roll-to-roll manufacturing process. Theelectrophoretic fluid used in the process may be universal to allmicrocups and it acts as a blanket on top of different colorants oradditives pre-filled in the microcups. Therefore, slight overflow of theelectrophoretic fluid between adjacent microcups during the subsequentsealing process would have no effect on the optical or electricalperformance of the display. In addition, the processes involve lowercosts and less processing steps than the processes currently availablefor the manufacture of multi-color electrophoretic displays.

In fact, the present invention has overcome the major obstacles involvedparticularly in the use of inkjet printing in the manufacture ofelectrophoretic displays. In other words, the two-step process hasenabled the use of inkjet printing in the roll-to-roll manufacture ofmulti-color electrophoretic displays.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic depiction of the electrophoretic display of thepresent invention.

FIGS. 2 a-2 e illustrate a process for manufacturing a multi-colorelectrophoretic display.

FIG. 3 shows a price tag prepared from a sectional electrophoreticdisplay.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

Unless defined otherwise in this specification, all technical terms areused herein according to their conventional definitions as they arecommonly used and understood by those of ordinary skill in the art.

The term “microcup” refers to the cup-like display cells as described inthe co-pending application, U.S. Ser. No. 09/518,488 filed on Mar. 3,2000 and U.S. Pat. No. 6,788,449. For ease of illustration, the term“microcup” is used in the description of the processes; however, it isunderstood that the usefulness of the processes of the present inventionis not limited to the microcup technology. The processes may be appliedto other technologies for the manufacture of electrophoretic displays.Therefore the term “microcup” broadly encompasses display cells of alltypes. The term “display cells”, in the present application, is broadlydefined as cavities to which materials such as colorant solutions ordispersions, additive solutions or dispersions or electrophoretic fluidsare filled.

The term “pattern-wise” is used to describe a process step which iscarried out in a pre-selected area.

The term “non-pattern-wise” is used to describe a process step which isnot carried out in a pre-selected area. Usually, a “non-pattern-wise”process step is carried out in a large area or an entire area.

I. Preparation of the Microcups

A general depiction of a microcup-based electrophoretic display is shownin FIG. 1. The display comprises two electrode plates (10, 11), at leastone of which is transparent (10), and a layer of microcups (12) enclosedbetween the two electrode plates. The microcups are filled with chargedpigment particles dispersed in a dielectric solvent or solvent mixtureand sealed with a polymeric sealing layer (13). When a voltagedifference is imposed between the two electrode plates, the chargedpigment particles migrate to one side or the other, causing either thecolor of the charged pigment particles or the color of the dielectricsolvent or solvent mixture to be seen through the transparent electrodeplate. One of the two electrode plates may be patterned.

The preparation of the microcup-based display cells may be accomplishedby microembossing or imagewise exposure as disclosed in the co-pendingapplication, U.S. Ser. No. 09/518,488 filed on Mar. 3, 2000(corresponding to WO01/67170) or by a pre-punched hole process asdisclosed in another application, U.S. Ser. No. 09/942,532 filed on Aug.29, 2001 (corresponding to WO03/019280), now U.S. Pat. No. 6,788,449,the contents of both of which are incorporated herein by reference intheir entirety.

II. Preparation of the Suspension/Dispersion

The microcups are filled with an electrophoretic fluid comprisingcharged pigment particles dispersed in a dielectric solvent or solventmixture. The dispersion may be prepared according to methods well knownin the art such as U.S. Pat. Nos. 6,017,584, 5,914,806, 5,573,711,5,403,518, 5,380,362, 4,680,103, 4,285,801, 4,093,534, 4,071,430,3,668,106 and IEEE Trans. Electron Devices, ED-24, 827 (1977), and J.Appl. Phys. 49(9), 4820 (1978). The charged pigment particles visuallycontrast with the medium in which the pigment particles are dispersed.The medium is a dielectric solvent or solvent mixture which preferablyhas a low viscosity and a dielectric constant in the range of about 2 toabout 30, preferably about 2 to about 15, for high particle mobility.Examples of suitable dielectric solvents include hydrocarbons such asdecahydronaphthalene (DECALIN), 5-ethylidene-2-norbornene, fatty oils,paraffin oil, aromatic hydrocarbons such as toluene, xylene,phenylxylylethane, dodecylbenzene or alkylnaphthalene, halogenatedsolvents such as perfluorodecalin, perfluorotoluene, perfluoroxylene,dichlorobenzotrifluoride, 3,4,5-trichlorobenzotrifluoride,chloropentafluoro-benzene, dichlorononane or pentachlorobenzene orperfluorinated solvents such as FC-43, FC-70 or FC-5060 from 3M Company,St. Paul Minn., low molecular weight halogen containing polymers such aspoly(perfluoropropylene oxide) from TCI America, Portland, Oreg.,poly(chlorotrifluoroethylene) such as Halocarbon Oils from HalocarbonProduct Corp., River Edge, N.J., perfluoropolyalkylether such as Galdenfrom Ausimont or Krytox Oils and Greases K-Fluid Series from DuPont,Delaware. In one preferred embodiment, poly(chlorotrifluoroethylene) isused as the dielectric solvent. In another preferred embodiment,poly(perfluoropropylene oxide) is used as the dielectric solvent.

The suspending medium may be colored by colorants (i.e., dyes orpigments). Nonionic azo and anthraquinone dyes are particularly useful.Examples of useful dyes may include, but are not limited to, Oil RedEGN, Sudan Red, Sudan Blue, Oil Blue, Macrolex Blue, Solvent Blue 35,Pylam Spirit Black and Fast Spirit Black from Pylam Products Co.,Arizona, Sudan Black B from Aldrich, Thermoplastic Black X-70 from BASF,anthroquinone blue, anthroquinone yellow 114, anthroquinone red 111,135, anthroquinone green 28 from Aldrich. Fluorinated colorants such asthose disclosed in copending patent applications, Ser. No. 10/439,428filed on May 15, 2003 and Ser. No. 10/903,923 filed on Jul. 29, 2004,the contents of both of which are incorporated herein by reference intheir entirety, are particularly useful when a perfluorinted solvent isused as the dielectric solvent.

In case of an insoluble dye or pigment, the dye or pigment forgenerating the color of the medium may also be dispersed in thedielectric medium. These dyes or pigments are preferably uncharged. Ifthe dyes or pigments for generating color of the medium are charged,they preferably carry a charge which is opposite from that of thecharged pigment particles. If the dyes or pigments carry the same chargeas the charged pigment particles, then they should have different chargedensity or different electrophoretic mobility. In any case, the dyes orpigments for generating color of the medium must be chemically stableand compatible with other components in the dispersion.

The charged pigment particles may be of an organic or inorganic dye orpigment, such as TiO₂, phthalocyanine blue, phthalocyanine green,diarylide yellow, diarylide AAOT yellow, and quinacridone, azo,rhodamine, perylene pigment series from Sun Chemical, Hansa yellow Gparticles from Kanto Chemical, and Carbon Lampblack from Fisher.Submicron particle size is preferred. The particles should haveacceptable optical characteristics, should not be swollen or softened bythe dielectric solvent and should be chemically stable. The resultingsuspension must also be stable against sedimentation, creaming orflocculation under normal operating conditions.

The pigment particles may exhibit a native charge, or may be chargedexplicitly using a charge control agent, or may acquire a charge whensuspended in the dielectric solvent. Suitable charge control agents arewell known in the art; they may be polymeric or non-polymeric in nature,and may also be ionic or non-ionic, including ionic surfactants such asAerosol OT, sodium dodecylbenzenesulfonate, metal soap, polybutenesuccinimide, maleic anhydride copolymers, vinylpyridine copolymers,vinylpyrrolidone copolymer (such as Ganex from International SpecialtyProducts), (meth)acrylic acid copolymers,N,N-dimethylaminoethyl(meth)acrylate copolymers. Fluorosurfactants areparticularly useful as charge controlling agents in perfluorocarbonsolvents. These include FC fluorosurfactants such as FC-170C, FC-171,FC-176, FC430, FC431 and FC-740 from 3M Company and Zonylfluorosurfactants such as Zonyl FSA, FSE, FSN, FSN-100, FSO, FSO-100,FSD and UR from Dupont. Charge control agents and surfactants ordispersants disclosed in copending patent applications, Ser. No.10/335,210 filed on Dec. 31, 2002, Ser. No. 10/335,051 filed on Dec. 31,2002, Ser. No. 10/632,171 filed on Jul. 30, 2003, Ser. No. 10/683,869filed on Oct. 9, 2003, Ser. No. 10/686,501 filed on Oct. 14, 2003, Ser.No. 10/976,152 filed on Oct. 27, 2004 and Ser. No. 10/976,244 filed onOct. 27, 2004, the contents of all of which are incorporated herein byreference in their entirety, are particularly useful when a fluorinatedsolvent is used as the dielectric solvent.

Suitable charged pigment dispersions may be manufactured by any of thewell-known methods including grinding, milling, attriting,microfluidizing, and ultrasonic techniques. For example, pigmentparticles in the form of a fine powder are added to the suspendingsolvent and the resulting mixture is ball milled or attrited for severalhours to break up the highly agglomerated dry pigment powder intoprimary particles. Although less preferred, a dye or pigment forgenerating color of the suspending medium may be added to the suspensionduring the ball milling process.

Sedimentation or creaming of the pigment particles may be eliminated bymicroencapsulating the particles with suitable polymers to match thespecific gravity to that of the dielectric solvent. Microencapsulationof the pigment particles may be accomplished chemically or physically.Typical microencapsulation processes include interfacial polymerization,in-situ polymerization, phase separation, coacervation, electrostaticcoating, spray drying, fluidized bed coating and solvent evaporation.

For a black/white electrophoretic display, the suspension comprisescharged white particles of titanium oxide (TiO₂) dispersed in a blacksolvent or charged black particles dispersed in a dielectric solvent. Ablack dye or dye mixture such as Pylam Spirit Black and Fast SpiritBlack from Pylam Products Co. Arizona, Sudan Black B from Aldrich,Thermoplastic Black X-70 from BASF, or an insoluble black pigment suchas carbon black may be used to generate the black color of the solvent.For other colored suspensions, there are many possibilities. For asubtractive color system, the charged TiO₂ particles may be suspended ina dielectric solvent of a cyan, yellow or magenta color. The cyan,yellow or magenta color may be generated via the use of a dye orpigment. For an additive color system, the charged TiO₂ particles may besuspended in a dielectric solvent of a red, green or blue colorgenerated also via the use of a dye or pigment. The red, green, bluecolor system is preferred for most applications.

III. Sealing of the Filled Microcups

The sealing of the microcups may be accomplished in a number of ways.One of the approaches is to disperse a UV curable composition into anelectrophoretic fluid containing charged pigment particles dispersed ina dielectric solvent or solvent mixture. The UV curable composition isimmiscible with the dielectric solvent or solvent mixture and has aspecific gravity preferably no greater than that of the dielectricsolvent and the charged pigment particles. The two components, the UVcurable composition and the electrophoretic fluid, are thoroughlyblended, for example, in an in-line mixer, and immediately coated intothe microcups with a precision coating mechanism such as Myrad bar,gravure, doctor blade, slot coating or slit coating. Excess fluid isscraped away by a wiper blade or a similar device. A small amount of aweak solvent or solvent mixture such as isopropanol, methanol or anaqueous solution thereof may be used to clean the residualelectrophoretic fluid on the top surface of the partition walls of themicrocups. Volatile organic solvents may be used to control theviscosity and coverage of the electrophoretic fluid. The thus-filledmicrocups are then dried and the UV curable composition floats to thetop of the electrophoretic fluid. The microcups may be sealed by curingthe supernatant UV curable layer during or after it floats to the top.UV or other forms of radiation such as visible light, IR and electronbeam may be used to cure and seal the microcups. Alternatively, heat ormoisture may also be employed to cure and seal the microcups, ifappropriate heat or moisture curable compositions are used. The sealingprocess referred to in this paragraph is the one-step sealing process.

The radiation curable composition for sealing may comprise a materialselected from the group consisting of polyvalent acrylate ormethacrylate, cyanoacrylates, polyvalent vinyl including vinylbenzene,vinylsilane and vinylether, polyvalent epoxide, polyvalent isocyanate,polyvalent allyl, and oligomers or polymers containing crosslinkablefunctional groups.

Thermoplastic elastomers may also be used as the sealing material.Examples of useful thermoplastic elastomers may include di-block,tri-block or multi-block copolymers represented by the formulas ABA or(AB)n in which A is styrene, α-methylstyrene, ethylene, propylene ornorbonene; B is butadiene, isoprene, ethylene, proplyene, butylene,dimethoylsiloxane or propylene sulfide; and A and B cannot be the samein the formula. The number, n, is ≧1, preferably 1-10. Representativecopolymers may include poly(styrene-b-butadiene),poly(styrene-b-butadiene-b-styrene), poly(styrene-b-isoprene-b-styrene),poly(styrene-b-ethylene/butylene-b-styrene),poly(styrene-b-dimethylsiloxane-b-styrene),poly((α-methylstyrene-b-isoprene),poly(α-methylstyrene-b-isoprene-b-α-methylstyrene),poly(α-methylstyrene-b-propylene sulfide-b-α-methylstyrene), andpoly(α-methylstyrene-b-dimethylsiloxane-b-α-methylstyrene). Additives,such as silica particles and surfactants, may be used to improve thefilm integrity and coating quality.

A preferred group of dielectric solvents exhibiting desirable densityand solubility discrimination against acrylate monomers and oligomersare halogenated hydrocarbons and derivatives thereof. Surfactants may beused to improve the adhesion and wetting at the interface between theelectrophoretic fluid and the sealing material. Useful surfactantsinclude the FC surfactants from 3M Company, Zonyl fluorosurfactants fromDuPont, fluoroacrylates, fluoromethacrylates, fluoro-substituted longchain alcohols, perfluoro-substituted long chain carboxylic acids andderivatives thereof.

Alternatively, the electrophoretic fluid and the sealing composition maybe coated sequentially into the microcups, if the sealing composition isat least partially compatible with the dielectric solvent. Thus, thesealing of the microcups may be accomplished by overcoating a thin layerof the sealing composition (which is curable by radiation, heat,moisture or interfacial reaction) on the surface of the electrophoreticfluid. Interfacial polymerization followed by UV curing is verybeneficial to the sealing process. Intermixing between theelectrophoretic fluid and the overcoat is significantly suppressed bythe formation of a thin barrier layer at the interface by interfacialpolymerization. The sealing is then completed by a post curing step,preferably by UV radiation. To further reduce the degree of intermixing,it is highly desirable that the specific gravity of the overcoating isno greater than that of the electrophoretic fluid. Volatile organicsolvents may be used to adjust the viscosity and the thickness of thecoating. When a volatile solvent is used in the overcoat, it ispreferably immiscible with the dielectric solvent. The two-step sealingprocess as described is particularly useful when the dye or pigment usedis at least partially soluble in the sealing composition.

IV. Preparation of Multi-Color Electrophoretic Displays

The process is carried out in multiple steps as illustrated in FIGS. 2a-2 e. The process involves filling colorant solutions or dispersions ofdifferent colors and charged pigment particles in two separate steps.More specifically, the process consists of at least two steps, (i)pattern-wise filling microcups with colorant solutions or dispersionsand, if necessary, evaporating the carrier solvent in the colorantsolutions or dispersions when it is different from the dielectricsolvent or solvent mixture in the electrophoretic fluid, and (ii)pattern-wise or non-pattern-wise filling an electrophoretic fluidcomprising charged pigment particles dispersed in a dielectric solventor solvent mixture into the microcups. In one embodiment, step (i) iscarried out before step (ii). In another embodiment, step (ii) iscarried out before step (i). However, it is preferred that step (i) iscarried out before step (ii).

The pattern-wise filling of the colorant solutions or dispersions may beaccomplished in a number of ways. For example, precision displacementtechnologies, such as inkjet printing and organic vapor phase depositionmay be used. The colorant solutions or dispersions of different colorsmay also be directly printed into the microcups. Suitable printingmethods may include, but are not limited to, flexo printing,lithographic printing, driographic or waterless lithographic printing,gravure printing, screen printing, thermal printing, laser ablativetransfer printing, strip coating and the like. If inkjet printing isused, Inkjet printer heads with multiple nozzles may be used tosimultaneously or sequentially deliver colorant solutions or dispersionsof different colors into microcups in predetermined areas.

As shown in FIG. 2 a, colorant solutions or dispersions (21) are filledinto microcups (20) in different areas. The areas are predetermined. Forexample, in a certain area, the microcups may be filled with a colorantsolution or dispersion of one color and, in another area, the microcupsmay be filled with a colorant solution or dispersion of another color.

The microcups may be formed on an electrode plate (28) and there may bea primer layer (not shown) between the electrode plate and themicrocups.

The pattern-wise filling of the colorant solutions or dispersions may beaccomplished in a number of ways. For example, the colorant solutions ordispersions of different colors may be directly filled into themicrocups in different areas.

Alternatively, the pattern-wise filling of the colorant solutions ordispersions of different colors into the microcups may be carried out bya method similar to that as disclosed in the co-pending application,U.S. Ser. No. 09/518,488 filed on Mar. 3, 2000. For example, the methodmay include laminating or coating all microcups with a positivelyworking photoresist, followed by imagewise exposing the positivelyworking photoresist to open the microcups in a predetermined area andthen filling the opened microcups with a colorant solution or dispersionof a first color, for example, by inkjet printing. These steps may berepeated to fill microcups with colorant solutions or dispersions ofdifferent colors in different areas. All of the filled microcups in thiscase may be top-sealed in one run by the one-step or the two-stepsealing process as described in Section III.

Another method for filling the microcups with colorant solutions ordispersions of different colors is similar to the one disclosed in aco-pending application, U.S. Ser. No. 10/284,586 filed on Oct. 30, 2002,and U.S. Pat. No. 6,545,797, the contents of both of which areincorporated herein by reference in their entirety. Briefly, the methodmay involve first filling all microcups with a filler material,overcoating the filled microcups with a positively working photoresist,opening the closed microcups in a predetermined area and removing thefiller material from the opened microcups and then filling the openedmicrocups with a colorant solution or dispersion of a first color. Thesesteps may be repeated to fill the microcups in different areas withcolorant solutions or dispersions of different colors. All of the filledmicrocups in this case may be top-sealed in one run by the one-step ortwo-step sealing process as described in Section III.

The colorant solution or dispersion is prepared by dissolving ordispersing a dye or pigment in a carrier solvent.

In one embodiment, the carrier solvent may be a dielectric solvent orsolvent mixture as described in Section II above. In this case, thecolorants must be soluble or dispersible in the dielectric solvent orsolvent mixture. The dielectric solvent or solvent mixture may be thesame as, or different from, the dielectric solvent or solvent mixture inthe electrophoretic fluid.

In another embodiment, the carrier solvent may be a common solvent orsolvent mixture, especially a common organic solvent or solvent mixture.Suitable common organic solvents may include, but are not limited to,hydrocarbons, alkyl ketones, alkyl esters, alcohols, ethers, water andmixtures thereof. If a common organic solvent is used as the carriersolvent, the colorant is still preferably soluble or dispersible in thedielectric solvent or solvent mixture in the electrophoretic fluid.

If inkjet printing is used, the colorant solutions or dispersions,according to the present invention, preferably have a surface tension inthe range of about 14 to about 50 dyne/cm, more preferably in the rangeof about 16 to about 45 dyne/cm.

The carrier solvent used for the colorant solutions or dispersions ispreferably volatile so that it may be removed easily.

The dyes or pigments in the colorant solutions or dispersions may be ofany color and preferably is thermally and photochemically stable. Thedyes or pigments are preferably soluble in the carrier solvent.

For inkjet printing, if not totally soluble, the particle size of thedye or pigment in the carrier solvent is preferably less than 1 um, morepreferably less than 0.1 um.

A surfactant or dispersant may be used to stabilize the dye or pigmentin the carrier solvent. A viscosity modifier may also be used to finetune the rheology of the colorant solutions or dispersions. Thesurfactant, dispersant or viscosity modifier, if used in the colorantsolutions or dispersions, should not interfere with the electrophoreticproperties of the final electrophoretic fluid. A fugitive surfactant ordispersant, such as a Surfynol® surfactant (from Air Product), isparticularly useful if the surfactant or dispersant used in the colorantsolutions or dispersions has a detrimental effect on the electrophoreticcharacteristics.

In one embodiment, the colorant solutions or dispersions may be ofdifferent colors. In another embodiment, the colorant solutions ordispersions may have the same dye or pigment, but with different opticaldensities or concentrations, so as to allow different shades of the samecolor. Therefore the term “different colors”, in the context of thepresent application, would also include “different shades of the samecolor”.

While it is not essential, it is preferred that the carrier solvent inthe colorant solutions or dispersions is removed after the colorantsolutions or dispersions have been filled into the microcups but beforethe charged pigment particles are introduced. The removal of the carriersolvent may be accomplished by, for example, heat or air flow. FIG. 2 bshows that only dried dyes or pigments remain in the microcups.

The introduction of the charged pigment (such as TiO₂ orTiO₂-containing) particles is accomplished by non-pattern-wise fillingan electrophoretic fluid (22) comprising charged pigment particles (23)dispersed in a dielectric solvent or solvent mixture (24) into microcupswhich are already filled with the colorants, as shown in FIG. 2 c.

The filling of the electrophoretic fluid may also be done pattern-wiseby methods described in copending patent applications, Ser. No.09/518,488 filed Mar. 3, 2000 and U.S. Pat. No. 6,545,797, the contentsof both of which are incorporated herein by reference in their entirety.

The charged pigment particles may be of the same color and thedielectric solvent or solvent mixture is preferably clear and colorless.All microcups may be filled with an electrophoretic fluid of the samecomposition.

Preferred dielectric solvents may include, but are not limited to, thosedescribed in Section II. The removal of the carrier solvent in thecolorant solutions or dispersions before introducing the electrophoreticfluid is preferred and even necessary if the carrier solvent mayinterfere with the subsequent top-sealing process.

The top-sealing of the filled microcups may be accomplished by methodsas described in Section III above. For example, the sealing may beaccomplished by adding a sealing composition into the electrophoreticfluid before filling the electrophoretic fluid into the microcups whichhave been pre-filled with colorants. The filled microcups are thensealed by curing the supernatant sealing layer (25) during or after itfloats to the top of the electrophoretic fluid. Heat or radiation suchas UV, visible light, IR and electron beam may be used to cure thesealing composition to seal the filled microcups. Alternatively, thesealing may be accomplished by overcoating a sealing composition ontothe electrophoretic fluid after the electrophoretic fluid has beenfilled in. The sealing layer (25) may be formed also by hardening of thesealing composition by radiation, heat, moisture or interfacialreaction. The sealing composition used in these methods preferably has aspecific gravity no greater than that of the electrophoretic fluid andpreferably is immiscible with the electrophoretic fluid. In the presentprocess, all of the filled microcups may be sealed in one run (FIG. 2 d)even though the microcups eventually are filled with electrophoreticfluids of different colors.

If step (ii) is carried out before step (i), the sealing is then carriedout with, or after, filling of the colorant solutions or dispersions. Inthis case, the sealing composition preferably has a specific gravity nogreater than that of the colorant solutions or dispersion. The sealingcomposition is also preferably immiscible with the colorant solutions ordispersions.

After the microcups are filled and top-sealed, the sealed microcups maybe laminated with an electrode plate (26), optionally pre-coated with anadhesive layer (27). The adhesive may be a pressure sensitive adhesive,a hot melt adhesive, a heat, moisture or radiation curable adhesive.

V. Preparation of Electrophoretic Displays Comprising Microcups Filledwith Electrophoretic Fluids of Different Characteristics

Electrophoretic displays comprising microcups filled withelectrophoretic fluids of different electrophoretic characteristics,such as switching rate, threshold voltage, gamma and/or clearingvoltage, may be manufactured by (i) first pattern-wise fillingmicrocups, for example, by inkjet printing, with additive solutions ordispersions providing the various characteristics, followed by (ii)pattern-wise or non-pattern-wise adding an electrophoretic fluidcomprising charged pigment (e.g., TiO₂ or other white or coloredpigments) particles dispersed in a dielectric solvent or solvent mixtureinto the microcups. The two steps, (i) and (ii), may be carried out in areversed order.

The microcups may be formed on an electrode plate and there may be aprimer layer between the electrode plate and the microcups.

The pattern-wise filling of the additive solutions or dispersions, forexample, by inkjet printing, may be carried out by any of the methodsdescribed in Section IV above for the pattern-wise filling of thecolorant solutions or dispersions.

The additive solution or dispersion is prepared by dissolving ordispersing an additive in a carrier solvent. If inkjet printing is used,the carrier solvent should be compatible with the inkjet process and theprinter head used. Useful additives for the present invention mayinclude, but are not limited to, surfactants, protective colloids,polymers, viscosity modifiers, charge controlling agents, stabilizers,antioxidants, fluorescent materials, fillers and filler particles.

Examples of useful additives may include, but are not limited to, thosedisclosed in co-pending patent applications, Ser. No. 10/335,210 filedon Dec. 31, 2002, Ser. No. 10/335,051 filed on Dec. 31, 2002, Ser. No.10/632,171 filed on Jul. 30, 2003, Ser. No. 10/683,869 filed on Oct. 9,2003, Ser. No. 10/686,501 filed on Oct. 14, 2003, Ser. No. 10/976,152filed on Oct. 27, 2004 and Ser. No. 10/976,244 filed on Oct. 27, 2004,the contents of all of which are incorporated herein by reference intheir entirety.

In one embodiment, the carrier solvent may be a dielectric solvent orsolvent mixture as described in Section II above. In this case, theadditive must be soluble or dispersible in the dielectric solvent orsolvent mixture, or adsorbed onto at least one of the charged pigmentparticles. The carrier solvent may be the same as, or different from,the dielectric solvent or solvent mixture in the electrophoretic fluidto be filled later.

In another embodiment, the carrier solvent may be a common solvent orsolvent mixture, especially a common organic solvent or solvent mixture.Suitable common organic solvents or solvent mixtures may include, butare not limited to, hydrocarbons, alkyl ketones, alkyl esters, alcohols,ethers, water and mixtures thereof. If a common organic solvent is used,the additive is still preferably soluble or dispersible in thedielectric solvent or solvent mixture in the electrophoretic fluid to befilled later.

The additive solution or dispersion preferably has a surface tension inthe range of about 14 to about 50 dyne/cm, more preferably in the rangeof about 16 to about 45 dyne/cm.

The carrier solvent is also preferably volatile so that it may beremoved easily.

The additive preferably is thermally and photochemically stable and ispreferably soluble in the carrier solvent. If not totally soluble, theparticle size of the additive in the carrier solvent is preferably lessthan 1 um, more preferably less than 0.1 um. The concentrations of theadditive in the additive solution or dispersion may be adjusted,depending on the specific needs.

A surfactant or dispersant may be used to stabilize the additiveparticles in the carrier solvent. A viscosity modifier may also be usedto fine tune the rheology of the additive solution or dispersion. Thesurfactant, dispersant or viscosity modifier, if used, should notinterfere with the electrophoretic properties of the finalelectrophoretic fluid. A fugitive surfactant or dispersant, such asSurfynol® surfactant (from Air Product), is particularly useful if thesurfactant or dispersant used in the additive solution or dispersion hasa detrimental effect on the electrophoretic characteristics.

Optionally, the carrier solvent of the additive solutions or dispersionsmay be dried off before the subsequent step of filling theelectrophoretic fluid.

The introduction of the electrophoretic fluid is accomplished bypattern-wise or non-pattern-wise filling as described in Section IVabove. In this case, the electrophoretic fluid may be colored.

The thus filled microcups are then top-sealed by one of the sealingprocesses described in the present application (e.g., Section III andSection IV). If step (ii) is carried out before step (i), the sealing isthen carried out with, or after, filling of the additive solutions ordispersions. In this case, the sealing composition has a specificgravity preferably no greater than that of the additive solutions ordispersion. The sealing composition is also preferably immiscible withthe additive solutions or dispersions.

After the microcups are filled and top-sealed, the sealed microcups maybe laminated with an electrode plate, optionally pre-coated with anadhesive layer. The adhesive may be a pressure sensitive adhesive, a hotmelt adhesive, a heat, moisture or radiation curable adhesive.

VI. Preparation of Sectional Electrophoretic Displays

In a sectional electrophoretic display, the display panel of anelectrophoretic display may be divided into sections and each sectionhas a two-color system. For example, a first section of the displaypanel has a red/white color combination, a second section has ablue/white color system and a third section has a green/white colorsystem.

The sections may be of any shapes or sizes. In one embodiment, thesections may be in the shape of stripes.

This type of sectional displays is particularly useful for largeelectronic signs and boards. FIG. 3 shows a price tag prepared from sucha sectional display. In area 3 a, the text and the background may have ared/white color combination whereas in area 3 b, the text and thebackground may have a blue/white color combination.

The sectional filling may be carried out in two steps as described inSection IV above. In other words, colorant solutions or dispersions ofdifferent colors and charged pigment particles are filled into themicrocups in two separate steps, as described in Section IV above.However, because of the display being a sectional display, the fillingdoes not have to involve masking and selective opening of the microcups.Instead, the colorant solution or dispersion of one color may be filledin an entire section.

For the sectional filling, alternative high through-put methods such ascoating and ultrasonic spraying may also be used to speed up themanufacturing process for manufacturing large signs and boards at lowcost.

An electrophoretic display having sections of different electrophoreticcharacteristics may also be similarly prepared according to the processof Section V above.

The thickness of the display produced by the present processes asdescribed can be as thin as a piece of paper. The width of the displayis the width of the coating web (typically 3-90 inches). The length ofthe display can be anywhere from inches to thousands of feet dependingon the size of the roll.

While the present invention has been described with reference to thespecific embodiments thereof, it should be understood by those skilledin the art, that various changes may be made and equivalents may besubstituted without departing from the true spirit and scope of theinvention. In addition, many modifications may be made to adapt aparticular situation, materials, compositions, processes, process stepor steps, to the objective, spirit and scope of the present invention.All such modifications are intended to be within the scope of the claimsappended hereto.

1. A process for the manufacture of an electrophoretic display, whichprocess comprises the steps of: (i) pattern-wise filling microcups withcolorant solutions or dispersions of different colors in differentpre-selected areas by inkjet printing, each of said colorant solutionsor dispersions comprising a colorant dissolved or dispersed in a carriersolvent, (ii) removing said carrier solvent in said colorant solutionsor dispersions to form colorant-containing cups, and (iii) filling saidcolorant-containing microcups with an electrophoretic fluid comprisingcharged pigment particles dispersed in a dielectric solvent or solventmixture in which said colorants are soluble or dispersible.
 2. Theprocess of claim 1 wherein said inkjet printing is carried out with aprinter head comprising multiple nozzles.
 3. The process of claim 1wherein said colorant solutions or dispersions are inkjet printed intothe microcups simultaneously or sequentially.
 4. The process of claim 1wherein said step (i) comprises laminating or coating onto saidmicrocups a positively working photoresist, selectively opening saidmicrocups in a predetermined area and filling the opened microcups witha colorant solution or dispersion of a predetermined color.
 5. Theprocess of claim 1 wherein said step (i) comprises filling saidmicrocups with a filler material, selectively opening the filledmicrocups in a predetermined area, removing the filler material from theopened microcups and filling the opened microcups with a colorantsolution or dispersion of a predetermined color.
 6. The process of claim1 wherein said colorant solution or dispersion is prepared by dissolvingor dispersing a dye or pigment in said carrier solvent.
 7. The processof claim 1 wherein said colorant solution or dispersion furthercomprises a surfactant, dispersant or viscosity modifier.
 8. The processof claim 7 wherein said surfactant or dispersant is a fugitivesurfactant or dispersant that is removable by heat, radiation or acombination thereof.
 9. The process of claim 1 wherein said carriersolvent is a dielectric solvent or solvent mixture.
 10. The process ofclaim 1 wherein said carrier solvent is a common solvent or solventmixture.
 11. The process of claim 10 wherein said common solvent orsolvent mixture is selected from the group consisting of hydrocarbons,alkyl ketones, alkyl esters, alcohols, ethers, water and mixturesthereof.
 12. The process of claim 1 wherein said electrophoretic fluidcomprises charged pigment particles of the same color dispersed in aclear and colorless dielectric solvent or solvent mixture.
 13. Theprocess of claim 1 further comprising top-sealing of the filledmicrocups with a sealing composition having a specific gravity nogreater than that of the electrophoretic fluid.
 14. The process of claim1 wherein said step of filling is carried out in sections and each ofsaid sections has a two-color system.
 15. The process of claim 1 whereinsaid carrier solvent is dried off in step (ii).
 16. A process for themanufacture of an electrophoretic display comprising microcups filledwith electrophoretic fluids having different electrophoreticcharacteristics, which process comprises the steps of: (i) pattern-wisefilling microcups with additive solutions or dispersions of differentelectrophoretic characteristics in different pre-selected areas byinikjet printing, each of said additive solutions or dispersionscomprising an additive dissolved or dispersed in a carrier solvent, (ii)removing said carrier solvent in said additive solutions or dispersionsto form additive-containing microcups, and (iii) filling saidadditive-containing microcups with an electrophoretic fluid comprisingcharged pigment particles dispersed in a dielectric solvent or solventmixture in which said additives are soluble or dispersible.
 17. Theprocess of claim 16 wherein the additive solution or dispersion isprepared by dissolving or dispersing an additive in said carriersolvent.
 18. The process of claim 17 wherein said additive is asurfactant, protective colloid, polymer, viscosity modifier, chargecontrolling agent, stabilizer, antioxidant, fluorescent material, filleror filler particles.
 19. The process of claim 16 wherein said carriersolvent is a dielectric solvent or solvent mixture.
 20. The process ofclaim 16 wherein said carrier solvent is a common solvent or solventmixture.
 21. The process of claim 20 wherein said common solvent orsolvent mixture is selected from the group consisting of hydrocarbons,alkyl ketones, alkyl esters, alcohols, ethers, water and mixturesthereof.
 22. The process of claim 16 wherein said electrophoretic fluidcomprises charged pigment particles dispersed in a colored dielectricsolvent or solvent mixture.
 23. The process of claim 16 furthercomprising top-sealing of the filled microcups with a sealingcomposition having a specific gravity no greater than that of theelectrophoretic fluid.
 24. The process of claim 18 wherein said carriersolvent is dried off in step (ii).